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Macro-Modelling of Laser Micro-Joints for Understanding Joint Strength in Electric Vehicle Battery Interconnects

Laser micro-welding is increasingly being used to produce electrically conductive joints within a battery module of an automotive battery pack. To understand the joint strength of these laser welds at an early design stage, micro-joints are required to be modelled. Additionally, structural modelling...

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Detalles Bibliográficos
Autores principales: Das, Abhishek, Beaumont, Richard, Masters, Iain, Haney, Paul
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2021
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8269514/
https://www.ncbi.nlm.nih.gov/pubmed/34202046
http://dx.doi.org/10.3390/ma14133552
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author Das, Abhishek
Beaumont, Richard
Masters, Iain
Haney, Paul
author_facet Das, Abhishek
Beaumont, Richard
Masters, Iain
Haney, Paul
author_sort Das, Abhishek
collection PubMed
description Laser micro-welding is increasingly being used to produce electrically conductive joints within a battery module of an automotive battery pack. To understand the joint strength of these laser welds at an early design stage, micro-joints are required to be modelled. Additionally, structural modelling of the battery module along with the electrical interconnects is important for understanding the crash safety of electric vehicles. Fusion zone based micro-modelling of laser welding is not a suitable approach for structural modelling due to the computational inefficiency and the difficulty of integrating with the module model. Instead, a macro-model which computationally efficient and easy to integrate with the structural model can be useful to replicate the behaviour of the laser weld. A macro-modelling approach was adopted in this paper to model the mechanical behaviour of laser micro-weld. The simulations were based on 5 mm diameter circular laser weld and developed from the experimental data for both the lap shear and T-peel tests. This modelling approach was extended to obtain the joint strengths for 3 mm diameter circular seams, 5 mm and 10 mm linear seams. The predicted load–displacement curves showed a close agreement with the test data.
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spelling pubmed-82695142021-07-10 Macro-Modelling of Laser Micro-Joints for Understanding Joint Strength in Electric Vehicle Battery Interconnects Das, Abhishek Beaumont, Richard Masters, Iain Haney, Paul Materials (Basel) Article Laser micro-welding is increasingly being used to produce electrically conductive joints within a battery module of an automotive battery pack. To understand the joint strength of these laser welds at an early design stage, micro-joints are required to be modelled. Additionally, structural modelling of the battery module along with the electrical interconnects is important for understanding the crash safety of electric vehicles. Fusion zone based micro-modelling of laser welding is not a suitable approach for structural modelling due to the computational inefficiency and the difficulty of integrating with the module model. Instead, a macro-model which computationally efficient and easy to integrate with the structural model can be useful to replicate the behaviour of the laser weld. A macro-modelling approach was adopted in this paper to model the mechanical behaviour of laser micro-weld. The simulations were based on 5 mm diameter circular laser weld and developed from the experimental data for both the lap shear and T-peel tests. This modelling approach was extended to obtain the joint strengths for 3 mm diameter circular seams, 5 mm and 10 mm linear seams. The predicted load–displacement curves showed a close agreement with the test data. MDPI 2021-06-25 /pmc/articles/PMC8269514/ /pubmed/34202046 http://dx.doi.org/10.3390/ma14133552 Text en © 2021 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Das, Abhishek
Beaumont, Richard
Masters, Iain
Haney, Paul
Macro-Modelling of Laser Micro-Joints for Understanding Joint Strength in Electric Vehicle Battery Interconnects
title Macro-Modelling of Laser Micro-Joints for Understanding Joint Strength in Electric Vehicle Battery Interconnects
title_full Macro-Modelling of Laser Micro-Joints for Understanding Joint Strength in Electric Vehicle Battery Interconnects
title_fullStr Macro-Modelling of Laser Micro-Joints for Understanding Joint Strength in Electric Vehicle Battery Interconnects
title_full_unstemmed Macro-Modelling of Laser Micro-Joints for Understanding Joint Strength in Electric Vehicle Battery Interconnects
title_short Macro-Modelling of Laser Micro-Joints for Understanding Joint Strength in Electric Vehicle Battery Interconnects
title_sort macro-modelling of laser micro-joints for understanding joint strength in electric vehicle battery interconnects
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8269514/
https://www.ncbi.nlm.nih.gov/pubmed/34202046
http://dx.doi.org/10.3390/ma14133552
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